Glazing with heat flux sensor and/or methods of making the same

ABSTRACT

Certain example embodiments relate to a glazing assembly including a first glass substrate. A radiation shield covering, directly or indirectly, at least a part of a peripheral edge area of the first glass substrate. A dual junction solid-state heat flux sensor includes a first junction oriented in the assembly at a first location at which radiation from a radiation source is receivable through the first glass substrate; a second junction oriented in the assembly at a second location that is blocked from the radiation source by the radiation shield; and circuitry configured to generate a signal based on a differential between transduced voltages respectively generated at the first and second junctions. A control module may be configured to receive the signal and selectively generate an action responsive thereto.

This application is a divisional of application Ser. No. 14/721,163,filed May 26, 2015, the entire disclosure of which is herebyincorporated herein by reference in this application.

TECHNICAL FIELD

Certain example embodiments of this invention relate to a glazing with aheat flux sensor, and/or a method of making the same. More particularly,certain example embodiments of this invention relate to using a singleor multiple junction solid-state heat flux sensor provided to a glazingto selectively trigger an appropriate action in response to detectedheat fluxes, and/or associated methods. Appropriate actions may include,for example, activation or deactivation of a switchable glazing,adjustment of a localized or central heating and cooling system,actuation of a vent etc. (e.g., with a view of energy efficienttemperature and comfort control).

BACKGROUND AND SUMMARY OF EXAMPLE EMBODIMENTS OF THE INVENTION

Motivated by building codes, national regulations, the general desire tosave energy, and/or the like, some building designers, architects, andowners make calculations and predictions about building energyconsumption. In general, it is desirable to reduce the energy a buildingconsumes, thereby potentially reducing total occupancy costs (e.g.,through lower heating and/or cooling costs), providing “greener” or moreenvironmentally-conscious structures, etc.

Windows are bi-directional energy pathways in a building envelope and assuch oftentimes have a large influence on the energy exchange balancebetween the building and its environment. Whether specifically marketedunder the name “net zero energy buildings” or a like term, there is atrend towards the construction of buildings that use no more energy thanthey produce.

Given this background, so-called “smart windows” or glazings that areable to individually measure the heat energy flux traversing throughthem are starting to have a reason to exist. For instance, smart windowscan in some instances allow lighting to be used more cost effectivelythrough improved light management, cut down on the use ofair-conditioning and heating through improved thermal management, etc.For instance, with respect to the former, switchable glazings (such as,for example, glazings incorporating polymer-dispersed liquid crystal(PDLC) materials, polymer-assembled liquid crystal (PALC) materials,electrochromic, electrochromic/photochromic hybrids, etc.) may beactivated or deactivated to allow more or less light to pass into (orredirected through) a building. In order to achieve the latter, forexample, it would be desirable to have information regarding the thermalflux through a building envelope, e.g., for localized and/or automatictemperature control and, thus, to make adjustments that have an impacton the overall building energy consumption.

In order to aid in achieving the above-identified and/or other aspects,it may be possible to integrate heat flux sensors into glazings. In thisregard, the inventor of the instant application has observed that heatflux incident on a building envelope sets up a temperature field orspatial temperature gradient, both perpendicular and parallel to theglazing. By measuring this temperature gradient (whether in a steadystate or transient mode), it becomes possible to measure with a highaccuracy the instantaneous heat flux through the window.

By simultaneously performing this measurement over several windowlocations on a building envelope or façade, one can compute theinstantaneous net heat flux (or its time differential) passing in to orout of a building envelope with high precision. This information can beused to trigger many different actions such as, for example, dimming orbrightening a switchable glazing, triggering localized heating orair-conditioning events in lieu of central functions, etc.

Such sensors may be small in size, possess power autonomy, and beintegrated with relative ease into modern glazings. Such sensors alsomay be used in automotive applications (such as, for example, laminatedin automotive sunroofs, windshields, etc.), refrigerator/freezer doors,etc. As such, they may be used to trigger automotive shades to beopened/closed to increase/decrease heat in the cabin of the vehicle,trigger cooling to help reduce the likelihood of food spoiling, etc.

In certain example embodiments of this invention, a glazing assemblyincluding a first glass substrate is provided. A radiation shieldcovering, directly or indirectly, at least a part of a peripheral edgearea of the first glass substrate. A dual junction solid-state heat fluxsensor includes a first junction oriented in the assembly at a firstlocation at which radiation from a radiation source is receivablethrough the first glass substrate; a second junction oriented in theassembly at a second location that is blocked from the radiation sourceby the radiation shield; and circuitry configured to generate a signalbased on a differential between transduced voltages respectivelygenerated at the first and second junctions.

According to certain example embodiments, a control module may beconfigured to receive the signal and selectively generate an actionresponsive thereto. For instance, the control module may be used toselectively trigger an action to be taken in a system external to theglazing and/or with respect to the glazing itself.

In certain example embodiments of this invention, a method of making aglazing assembly is provided. The method comprises: covering, directlyor indirectly, at least a part of a peripheral edge area of a firstglass substrate with a radiation shield; connecting a dual junctionsolid-state heat flux sensor to the first glass substrate, so that afirst junction of the sensor is oriented in the assembly at a firstlocation at which radiation from a radiation source is receivablethrough the glass substrate, and a second junction of the sensor isoriented in the assembly at a second location that is blocked from theradiation source by the radiation shield; and providing circuitryconfigured to generate a signal based on a differential betweentransduced voltages respectively generated at the first and secondjunctions.

Methods of using the glazings described herein also are provided incertain example embodiments.

The features, aspects, advantages, and example embodiments describedherein may be combined to realize yet further embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages may be better and morecompletely understood by reference to the following detailed descriptionof exemplary illustrative embodiments in conjunction with the drawings,of which:

FIG. 1 is a diagram showing the working principal behind a thermalradiation detector, including the signal generation, the main sources ofnoise, and the resulting specific detectivity, which may be used inconnection with certain example embodiments;

FIG. 2 a simplified schematic view of a cross-section of a glazing,including a differential mode flux sensor and associated circuitry,which may be used in connection with certain example embodiments;

FIG. 3 is an example insulating glass (IG) unit incorporating theglazing of FIG. 2, in accordance with certain example embodiments;

FIG. 4 is an example laminated glazing incorporating the glazing of FIG.2, in accordance with certain example embodiments;

FIG. 5 is an example vacuum insulating glass (VIG) unit incorporatingthe glazing of FIG. 2, in accordance with certain example embodiments;

FIG. 6 is an example switchable glazing incorporating the glazing ofFIG. 2, in accordance with certain example embodiments;

FIG. 7 is a block diagram showing control electronics that may be usedin connection with certain example embodiments;

FIGS. 8a-8b show how two different example flexible substratesincorporating heat flux sensors may be structured and arranged for usein an example window application, in accordance with certain exampleembodiments;

FIGS. 9a-9b show the arrangements in FIGS. 8a-8b being inserted into anexample laminated window product, in accordance with certain exampleembodiments;

FIG. 10 is a flowchart showing an example process for sensing heat fluxand taking an appropriate follow-up action, which may be used inconnection with certain example embodiments; and

FIG. 11 is a block diagram showing how hardware and software elementsmay be configured, in accordance with an example embodiment.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

Certain example embodiments relate to glazings with heat flux sensors,and/or methods of making the same. Direct measurement of glass surfacetemperature using thermocouples can be very challenging, as bothaccuracy and precision can be affected by exposure to direct sunlight,as well as energy exchange with convective air currents. Winds and/orother loads on a window can, for example, causethermo-decoupling/de-bonding of thermal contacts.

Certain example embodiments therefore use a dual junction solid-stateheat flux sensor whereby incident heat flux can be extracted by havingone junction exposed directly to the heat source (radiative, convective,or conductive), while the other junction is thermally isolated andshielded from the source. The operation principle is based on a two-stepsensing process in certain example embodiments. That is, in certainexample embodiments, the process involves radiation to thermaltransduction, and thermal to electrical transduction. Furtherinformation can be found in, for example, U. Dillner et al.: Figures ofmerit of thermoelectric and bolometric thermal radiation sensors, J.Sens. Sens. Syst., 2, 85-94, 2013, as well as R. C. Jones: A newclassification system for radiation detectors, J. Opt. Soc. Am., 39,327-343, 1949—the entire contents of each of which are herebyincorporated herein by reference.

In this regard, and referring now more particularly to the drawings inwhich like reference numerals indicate like parts throughout the severalviews, the FIG. 1 diagram shows the working principal behind a thermalradiation detector, including the signal generation, the main sources ofnoise, and the resulting specific detectivity, which may be used inconnection with certain example embodiments. An absorber layer is usedto convert incident radiation to heat energy. The absorber layer mayinclude a high-emissivity material such as, for example, black frit,carbon epoxy, soot, a material including carbon black, carbon nanotubes,and/or the like.

The optical domain thus receives input radiation power (P_(opt)), whichis converted into an intermediate signal indicative of information inthe thermal domain. The intermediate signal is converted into theelectrical output signal using a temperature (difference) transducer.More particularly, the intermediate signal (ΔT=εP_(opt)/G) indicatesthat the temperature difference (ΔT) is equal to the absorber value (ε)multiplied by the input radiation power, divided by the heat conductance(G).

The thermal sensor principle constitutes the fundamental differencebetween thermal and photonic radiation sensors (e.g., photoconductors orphotodiodes or solar cells) based on quantum detection. Desirablefeatures of thermal sensors may in certain example implementationsinclude uncooled operation and broadband response (e.g., over theinfrared spectrum as enabled by appropriate volume absorbers or thelike). Some radiation sensors may require sunlight and thus be limitedto daylight applications.

Radiation sensors can be characterized by several measured quantitiessuch as, for example, responsitivity, time constant, and noiseequivalent power (NEP), which can be significant parameters whenassessing the suitability of a given radiation sensor for a specificapplication. For a comparison of various radiation sensors, it isexpedient to condense these parameters, preferably into a single numberserving as a figure of merit, which can help the potential user of thesesensors to rate its performance (and in essence help as a sort ofcalibration).

The thermal isolation structure, which is necessary to generate thetemperature difference ΔT as the intermediate signal of the thermalsensor, is characterized by its heat capacitance C and heat conductanceG. If it is assumed t that the thermal isolation structure is a film ofthickness d and a size essentially comprising the receiving area A ofthe sensor, which results in a volume V=Ad, then the heat capacitancecan be readily calculated from the corresponding specific quantities,i.e., the volumetric heat capacity c_(V) and the heat capacity per unitarea c_(A)=c_(V)d, so that:C=c _(V) V=c _(A) A  (1)

The heat conductance results from the temperature difference ΔTgenerated by the heat load P applied at the membrane according to:G=P/ΔT.  (2)

Corresponding to the membrane geometry, it can be useful to relate thethermal conductance to the receiving area by a heat transfercoefficient:U=G/A.  (3)

The total heat transfer comprises three components: Heat transfer byradiation (U_(R)), by conduction of the functional layers forming thetemperature transducer (U_(C)), and by parasitic heat flows (U_(P))originating, for example, from a surrounding gas atmosphere or anylayers of the thermal isolation structure other than the functionallayers considered above. Thus:s=Σ _(i) U _(i) =U _(R) +U _(C) +U _(P),  (4)(index i=R, C, P). The heat transfer by radiation sets a minimum for thetotal heat transfer. Its heat transfer coefficient can be calculatedfrom Stefan's law, assuming ΔT<<T, which results inU _(R)=4_(εσ) _(SB) T ³  (5)

Here ε is the absorptivity or emissivity of the receiving area, σ_(SB)the Stefan-Boltzmann constant, and T the operational temperature.Equation (5) yields Ur=6.12 W m⁻² K⁻¹ at T=300 K and ε=1. The heattransfer by conduction of the functional layers is proportional to theirthermal conductivity κ. Thus:U _(C) =κ/g,  (6)where g is a geometric factor related to the dimensions of the sensorand thus expressed in length units.

The voltage difference between the exposed junction and the shielded (or“hidden”) junction is given by:

$\begin{matrix}{{{\Delta V} = {\frac{S\; ɛ}{A_{s}}\left( {P_{inc} - P_{amb}} \right)}},} & (7)\end{matrix}$where S is the Seebeck coefficient (which will be recognized by thoseskilled in the art as being a measure of the magnitude of an inducedthermoelectric voltage in response to a temperature difference acrossthat material), A_(s) is the area of the sensor, P_(inc) is the power ofthe incident radiation (heat), and P_(amb) is the power of the ambientradiation (heat). This follows because the incoming heat flux Q is equalto the power of the incident radiation (heat) divided by the area of thesensor (Q=P_(inc)/A_(s)).

This differential scheme may be achieved via a differential op-ampcircuitry, which lends itself to amplification with a gain. This allowsthe signal-to-noise ratio to be improved as well as ambient noisecancellation. For instance, typical blackbody materials (e.g., of orincluding silicon) may produce signals on the orders of millivolts(e.g., up to 10, 20, 30, or more millivolts), but op-amp circuitry maybe used to increase the gain by 60-1,000 times (or even more) in certainexample embodiments, e.g., to make the signal more usable. FIG. 2 is asimplified schematic view of a cross-section of a glazing, including adifferential mode flux sensor and associated circuitry, which may beused in connection with certain example embodiments. That is, FIG. 2includes a glass substrate 202 with a radiation shield 204. Theradiation shield may be, for example, a black frit perimeter, a sash,bezel, frame, or the like. When light impinges on the substrate 202, itsets up a temperature profile or gradient in the glass. The temperatureprofile or gradient may have heat flux in any directions spanning bothparallel and perpendicular to the glass. An example profile 206 is shownin FIG. 2, although it will be appreciated that other profiles may existbased on, for example, position of the sun relative to the window, etc.

A first junction 208 is directly exposed to the incoming radiation andthus may be considered the hot junction. On the other hand, a secondjunction 210 is shielded from the incoming radiation by the radiationshield 204, it may be considered the cold junction. The differencebetween the sensed temperature at the hot and cold junctions provides avoltage (such that, for example, V=S(T_(h)−T_(c))), which may beprocessed at the op-amp circuitry 212, e.g., to produce a voltage 214that is proportional to the incoming heat flux Q (where Q=K V/S).

The sensors may be integrated in one chip package. The chip package maycontain several junctions that are connected in series. For example,there may be two sets of junctions, namely the hot and cold junctions.The chip package may then be affixed or soldered on flexible printedcircuit boards (FPCs) with two metal pads (hot and cold), in certainexample embodiments. For simplicity, certain example embodiments mayinvolve the two junctions being fabricated using poly-Si to have thesame Seebeck coefficient S, U_(s) value, detection area A_(s), andemissivity ε. Then, the sensor voltage allows for the calculation ofheat flux using equation (7) above. Furthermore, by further havingaccess to the temperature difference between the two junctions, theU-value of the glazing can be deduced, as follows:

$\begin{matrix}{U_{glazing} = {\frac{\Delta V}{d\; T_{j}} = {{\frac{S\; ɛ}{A_{s}U_{s}} \times \frac{\left( {P_{inc} - P_{amb}} \right)}{\Delta\; T}} = {\frac{\Delta V}{\Delta\; T_{j}} \times \frac{U_{s}}{S\; ɛ}}}}} & (8)\end{matrix}$

In certain example embodiments, the area of the sensor may be selectedso as to help control the rate at which the sensor output changes. Ithas been found that sensors that change output too quickly and thatchange too slowly are undesirable. With regard to the former, forexample, erroneous detections may be made and thus erroneous actionsmade be triggered (e.g., unless downstream noise reduction, filtering,correlation techniques, and/or the like are implemented to help avoidsuch false positives). With regard to the latter, for example, rapidthough bona fide changes may not be detected, thereby leading topotentially harder to correct false negative situations.

The glazing of FIG. 2 may be used with or otherwise incorporated into avariety of different assemblies. For example, FIG. 3 is an exampleinsulating glass (IG) unit incorporating the glazing of FIG. 2, inaccordance with certain example embodiments. As shown in FIG. 3, asecond substrate 302 is provided in substantially parallel spaced apartrelation to the first substrate 202. A spacer or spacer system 304 helpsmaintain the first and second substrates 202 and 302 in this orientationand helps define a gap, space, or cavity 306 therebetween. The gap 306may be filled with gas including an inert gas (e.g., Ar, Xe, Kr, or thelike), with or without oxygen, in certain example embodiments. Incertain example embodiments, the gap may be at least partially evacuatedand filled with 80% argon and 20% oxygen or air.

As another example, FIG. 4 is an example laminated glazing incorporatingthe glazing of FIG. 2, in accordance with certain example embodiments.As shown in FIG. 4, the first substrate 202 and the second substrate 302are laminated to one another using at least one laminating interlayer402. The at least one laminating interlayer 402 may include, forexample, PVB, EVA, PET, PU, PMMA, and/or the like. In general, anypolymer-inclusive interlayer, epoxy-based, or other material may be usedto help secure together the first substrate 202 and the second substrate302. In certain example embodiments, the sensor may be embedded in itsown laminating layer, e.g., for protection purposes.

As another example, FIG. 5 is an example vacuum insulating glass (VIG)unit incorporating the glazing of FIG. 2, in accordance with certainexample embodiments. As shown in FIG. 5, an edge seal 502 (e.g., of orinclude a frit material) is provided around the periphery of the firstsubstrate 202 and/or the second substrate 302, and spacers or pillars504 are provided in the cavity 506 provided between the first and secondsubstrates 202 and 302. The cavity is evacuated to a pressure less thanatmospheric, e.g., through a pump-out port or the like. The edge seal502 helps to hermetically seal the VIG unit.

As yet another example, FIG. 6 is an example switchable glazingincorporating the glazing of FIG. 2, in accordance with certain exampleembodiments. The FIG. 6 switchable glazing may include an active layeror layer stack 602. For instance, the active layer or layer stack 602may be a PDLC film, a PALC film, an electrochromic film, and/or thelike. In the case of a PDLC or a PALC film, for instance, it may beadvantageous to sandwich the film between first and second laminatinglayers 402 a and 402 b, in certain example embodiments. Exampleelectrochromic coatings, fabrication methods, and the like that may beused in connection with certain example embodiments described herein aredisclosed in, for example, U.S. Pat. Nos. 8,289,610; 7,547,658;7,545,551; 7,525,714; 7,511,872; 7,450,294; 7,411,716; 7,375,871; and7,190,506, the entire contents of each of which is hereby incorporatedherein by reference. Example PDLC coatings, fabrication methods, and thelike that may be used in connection with certain example embodimentsdescribed herein are disclosed in, for example, U.S. Publication Nos.2014/0176836 and 2009/0115922, and Ser. No. 14/466,217 filed on Aug. 22,2014, the entire contents of each of which is hereby incorporated hereinby reference.

It will be appreciated that although certain example configurations havebeen provided, still other configurations are possible. For example, itis possible to move the junctions to another surface such as, forexample, the second, third, or fourth surface in an IG, VIG, laminated,and/or other product. Frit may be provided on any one or more surfacessuch as, for example, the first and fourth, second and third, first andthird, and/or other combinations of one, two, three, or four surfaces,in different example embodiments. The glass and/or laminating materialsmay be tinted in certain example embodiments. In certain exampleembodiments, the glass may be heat treated (e.g., heat strengthenedand/or thermally tempered), chemically strengthened, and/or the like. Incertain example embodiments, one or more glass substrates may bereplaced with other materials such as, for example, plastics, polymers,and/or the like. Thus, vacuum insulating panels (VIPs) are alsocontemplated herein.

It will be appreciated that the example glazings described herein may beused in a number of different applications including, for example,residential and/or commercial window applications, automotiveapplications, skylights, merchandizers (e.g., refrigerator and/orfreezer doors), display packages, solar cells, greenhouses, etc. IGand/or VIG units may, for example, be used merchandizers, IG units maybe used for building windows and/or skylights, laminated products may beused in automotive applications, etc. In greenhouse applications, forexample, the technology used herein may be used to determine when toallow in more/less sunlight (e.g., for different plants that benefitfrom different amounts of sunlight, to build/reduce heat, etc.), when tovent an area (e.g., based on interior and/or exterior heat, etc.

Depending on the size of the envelope to be monitored, more or fewersensors may be provided. For example, a typical automotive applicationmay benefit from the presence of 2-3 sensors. A typicalrefrigerator/freezer similarly may benefit from the presence of 2-3sensors. A commercial building window may occupy more space and thus maybenefit from 3 or more sensors in some instances. Different embodimentsmay use more of fewer sensors.

In certain example embodiments, multiple sensors may be connected inseries for one or both junctions, e.g., to create a larger temperaturedifferential. This may be advantageous in some instances, e.g., as itmay help to improve the accuracy of the measurements, while stillmaintaining small size sensors that react at appropriate rates.Minimization of the U-values may be advantageous for similar reasons andthus may be performed in certain example embodiments.

Referring once again to the drawings, FIG. 7 is a block diagram showingcontrol electronics that may be used in connection with certain exampleembodiments. The example control unit 702 shown in FIG. 7 may be locatedon a common printed circuit board (PCB) as one or both junctions, or itmay be located remote from the window. Input 214 from the sensor isreceived by the control unit 702 through a suitable interface. Acontroller 704, which may include one or more processors, ASICs, and/orthe like, receives the input 214 and may store it in the memory 706. Inthis regard, historical data and/or the like may be stored to the sensordata store 706 a section of the memory 706. The memory 706 may be anysuitable combination of transitory or non-transitory memory such as, forexample, RAM, ROM, flash memory, and/or the like. The controller 704 mayconsult stored instructions 706 b to determine when and/or how to act onstored sensor data. For instance, pre-programmed rules may specify whento activate a switchable coating, turn on/off internal lighting,when/how to adjust a central HVAC unit, when/how to adjust a localizedHVAC unit, etc. For instance, a temperature increase beyond a certainlevel over a predefined amount of time (e.g., a 5 degree increase over a3 hour period) may trigger a switchable glazing to be changed to anon-transmissive state, local cooling, etc. A more rapid temperatureincrease may trigger central HVAC action. Similarly, high flux mayindicate a significant amount of ambient light and thus may dim internallighting as external lighting may be usable instead. The rules foractivating HVAC systems may be based on published standards that linkthe outside temperature to the temperature to be maintained incommercial office buildings, best practice guidelines for maintaining anenergy efficient home, etc.

In a similar fashion, vehicle sunroofs, vehicle windows, vehicleheating/cooling systems, etc., may be made to react. With respect to theformer, mechanical shades may be closed, switchable glazings may beactivated/deactivated, etc. Merchandizers may receive extra cooling whenheat is detected (e.g., from a sunny day, a hand pressed against a glasswindow, etc.).

The various actions that are performable by the control unit 702 may beperformed in connection with a series of interfaces. In this regard,FIG. 7 shows example interfaces for a central HVAC 708 a, a local HVAC708 b, a switchable glazing 708 c, and lighting 708 d. It will beappreciated that more or fewer interfaces may be provided in differentembodiments, e.g., based on the end application, the desired controls,etc.

In certain example embodiments, a diagnostics module 710 may run underthe control of the controller 704 and potentially based on theinformation stored in the sensor data store 706 a. The diagnosticsmodule 710 may track the effective U-value or R-value of a window overtime, which may be used to determine whether the window is failing,whether it is possible that an inert gas might be leaking out of an IGunit (thereby potentially posing a health or safety risk), whether it ispossible that a VIG is losing vacuum, whether it is possible that amirror in a solar application (e.g., an application including aconcentrating solar photovoltaic mechanism, a concentrating solarmechanism with a heating tube or the like, a secondary reflector panel,and/or the like) is failing, etc. The diagnostics module 710 may causean alarm to be raised, e.g., by wirelessly or otherwise transmittinginformation about a failure or expected failure to a remote system(e.g., a local or remote computer system, an application on an owner'ssmart device or computer, etc.), by causing an LED or other light toblink in a particular way (e.g., different color lights, blinkingpatterns, and/or the like to signal each different kind of failure thatis tracked, etc.), and/or the like. The control unit 702 thus mayinclude a wireless transmitter and/or may be operably connected to oneor more indicator lights and/or the like.

FIGS. 8a-8b show how two different example flexible substratesincorporating heat flux sensors may be structured and arranged for usein an example window application, in accordance with certain exampleembodiments. Each of FIGS. 8a-8b includes a heat sensor 802 located inthe approximate center of each of the flexible substrates. The topsurfaces of the flexible substrates support the hot junctions 804 (e.g.,including a material such as, for example, copper or the like), and thebottom surfaces of the flexible substrates support the cold junctions806 (e.g., also including a material such as, for example, copper or thelike). As will be appreciated from FIGS. 8a-8b , the areas of the twocontacts have almost the same dimensions in certain example embodimentsand are provided on opposite sides of the same substrate (e.g., the sameor similar heights and widths that differ from one another by no morethan 20% in some examples, no more than 15% in other examples, and nomore than 10% in still other examples). It will be appreciated that twoor more sensor may be connected in series to amplify the output voltageprior to amplification, in certain example embodiments.

Metallized vias may be provided for thermalizing the system. The hotjunction at the chip level therefore can be made hot and provide goodthermal contact(s), while still permitting the system to functionproperly and provide a temperature gradient that is useful. The viasshown in the enlargement aid in thermally connecting the pad to the chipin certain example embodiments. There are also vias for electricalconnection to chip in certain example embodiments.

Each of the substrates is adapted to be folded in certain exampleembodiments. The FIG. 8a example shows folding into an example “C” shape(including where an example fold line could be located), and the FIG. 8bexample shows folding into an example “Z” shape (including where examplefold lines could be located). These arrangements could be inserted intoany of the products described herein. In this regard, FIGS. 9a-9b showthe arrangements in FIGS. 8a-8b being inserted into an example laminatedwindow product, in accordance with certain example embodiments. Forinstance, as shown in FIG. 9a , the bend proximate the curve of the “C”is inserted through a slit formed in the laminate (e.g., a PVBlaminate), and a hole formed in the laminate accommodates the sensor.The laminate wedge is laminated between two substrates. The FIG. 9bapproach includes one hole for accommodating the folds of the substrateand the sensor. It will of course be appreciated that other flexiblesubstrate designs, laminate arrangements, and/or the like, may be usedin connection with different example embodiments.

FIG. 10 is a flowchart showing an example process for sensing heat fluxand taking an appropriate follow-up action, which may be used inconnection with certain example embodiments. A dual junction solid-stateheat flux sensor or the like, e.g., as shown in FIG. 2, is used togenerate voltage proportional to heat flux in step S1002. In step S1004,the generated voltage is forwarded to control electronics, e.g., asshown in FIG. 7, for possible follow-up action. Based on current and/orhistorical data from the sensor, a determination is made in step S1006as to a follow-up action to be taken. The follow-up action may, forexample, include sending a control signal to an external element via asuitable interface, store the received data (e.g., a temperaturedifference with a timestamp, identifier of the sensor that provided thedata, etc.), and/or the like. The follow-up action is taken in stepS1008, e.g., based on the determination reached in step S1006.

Samples

Samples were manufactured for preliminary testing purposes. In suchsamples, a layer of frit was deposited around at least one of a firstand second substrates' peripheral edges on one side (or on one sideeach), and a layer comprising PVB was sandwiched therebetween. In someof these samples, PDLC foils were laminated within a glass structureinside a PVB matrix. The PDLC layer was switchable between opaque andtransparent by the application of an electric field across it. The fiveconfigurations tested were as follows:

Sample 1: Clear glass with frit/0.76 mm PVB/0.76 mm PVB/clear glass withfrit

Sample 2: Clear glass with frit/0.76 mm PVB/0.38 mm PVB/PDLC switchablelayer with connections/0.76 mm PVB/clear glass with frit

Sample 3: Tinted glass with frit/0.76 mm PVB with tint/0.38 mm PVB/clearglass

Sample 4: Clear glass with frit/0.76 mm PVB/0.38 mm PVB/PDLC switchablelayer with connections/0.38 mm PVB/clear glass with frit

Sample 5: Tinted glass with frit/0.76 mm PVB with tint/0.38 mmPVB/tinted glass with frit

For each sample, three modes of sensor configuration were involved.These modes included conduction, absorber, and reflector modes. Theconduction mode measured heat flow between surfaces 2 and 3 of theassembly. The absorber mode measured radiation heat flow between a blackpatch on the sensor and surface 3. The reflector mode measuredconvective heat flow exchange between a white patch (e.g., of or includesilver) on the sensor and an air gap (in case of an IG).

These three modes allow one to measure the heat flux, as well as theU-value of the glazing. It will be appreciated that greater precision ofthe U-value can be obtained by measuring the ΔT between two surfaces. Incertain example embodiments, it is possible to segregate multiplesensors to measure these three modes more individually. Then, it becomespossible, for example, to solve a system with three equations to moreinstantaneously fingerprint and/or more longitudinally track theperformance of the glazing on a system level.

Conductive sensors included 800 micron thick chips on a 1.6 mm thick PCBsubstrate, thermally connected to surfaces 2 and 3, with the connectionfrom the PCB to surface 2 being accomplished using a copper pillar. Forthe conductive sensors, serigraphy was used to provide metallic thermalspreaders on surfaces 2 and 3. Radiative sensors included chips on 1.6mm thick PCB substrate, thermally connected to surface 3. For theradiative sensors, serigraphy was used to provide metallic thermalspreaders on surface 3. For all sensors, a reflective Scotch tape wasused to cover the chips, the PCB-to-surface 3 thermal connection and theelectrical wiring, to help avoid thermal noise and improve sensitivity.

Preliminary measurements were carried out on the sensors during thecourse of the assembly, e.g., to help determine whether the examplesensors were able to withstand typical lamination processes. Thesemeasurements included checks for sensor internal resistance (measured inMΩ, typically around 33MΩ); backside thermal contact resistance (anempirical check using ice to check the sensor response to cold appliedto surface 4 behind the sensor); and front-side thermal contactresistance (an empirical check using ice to ensure the sensor's responseto cold applied to surface 1 above the sensor).

Following assembly, the sensors' response to various stimuli such asintentional heat, cold, and infra-red light was assessed. Themeasurements were carried out using either 3 Sineax V604 analog signalacquisition modules or LNA/ADC cards (up to 6) on an I²C bus with anAardvark controller.

In all cases, the sensors' internal resistance was unchanged, confirmingthat the lamination process (which include a 270° C. tacking furnace anda production autoclave) had no measurable impact on the sensors.

FIG. 11 is a block diagram showing how hardware and software elementsmay be configured, in accordance with an example embodiment. FIG. 11shows first and second sensors 1102 a and 1102 b, with respective hotand cold junctions 1104 a-b and 1106 a-b connected to or otherwiseformed on respective analog-digital control (ADC) boards 1108 a-1108 band with respective amplifiers 1110 a-1110 b. The ADC boards 1108 a-1108b are connected to a first micro-controller 1112 a. Thus, a thermocouple1114 a is in essence formed for a first room or zone. The firstmicro-controller 1112 a communicates with a main processor 1116 via aCAN, LIN, or other data bus. The system is powered by a power supply1120. Based on programming of the main processor 1116, a heating/coolingunit 1122 a for a first room or zone can be controlled.

As will be appreciated from FIG. 11, a similar arrangement is providedfor a second room or zone. That is, third and fourth sensors 1102 c-1102d are provided with respective hot and cold junctions 1104 c-d and 1106c-d and are connected to or otherwise formed on respective ADC boards1108 c-1108 d. The ADC boards 1108 c-1108 d are connected to a secondmicro-controller 1112 b, in essence forming another thermocouple 1114 bfor this second room or zone. The second micro-controller 1112 b alsocommunicates with a main processor 1116 via a CAN, LIN, or other databus, and the main processor 1116 can take actions with respect to theheating/cooling unit 1122 b for the second room or zone.

FIG. 11 shows two sensors in two zones. However, it will be appreciatedthat more or fewer sensors may be provided for any number of zones. Forinstance, for large areas, multiple sensors may be provided. One or morebusses may be provided for connecting to one or more main processors.

The ADC boards 1108 a-1108 d may include connectors (e.g., wires) forthe sensors 1102 a-1102 d, respective, as well for connections to theCAN bus 1118 (e.g., for input and output) either directly or via themicro-controllers 1112 a-1112 b, respective, in different exampleembodiments. On-board ADC functionality (e.g., for converting the rawsensor data into digital signals relayable over the CAN bus 1118) may beprovided in certain example embodiments. In other example embodiments,the micro-controllers 1112 a-1112 b may be used for this and/or otherpurposes. A voltage regulator also may be provided on-chip.

The main processor 1116 may be a part of a computer or the like. Incertain example embodiments, software modules of such a computer mayfacilitate the receipt and processing of data from the sensors 1102a-1102 d. For example, application programming interfaces (APIs) mayfacilitate the retrieval of raw sensor data, the sending of controlsignals (e.g., report sensor data, cycle on/off, etc.), and/or the like.A control software module may process data and generate otherinformation for visualization, reporting, etc. For example, real-timegraphs of processed sensor data (e.g., indicating temperature at thesensor(s), temperature gradient across the product, etc.) may bedisplayed (e.g., on a display communicatively coupled to the computer),etc. More historical log files may be generated, processed and/or storedin an Excel spreadsheet or other like spreadsheet or database file, andthey may be used to create graphs and/or other visualizations, as well.

It will be appreciated that multiple junctions, both multiple hot andmultiple cold junctions, may be provided on a single chip in certainexample embodiments. For instance, a single chip for a single zone mayinclude many junctions in series all inside the chip, but to the outsideeach chip may have two input electrodes, one hot and one cold.

It will be appreciated that the FIG. 11 example configuration is justone sample, and that other hardware and/or software configurations maybe usable in window and/or other products.

Although certain example embodiments schematically illustrate the hotjunction of the sensor being in a central area of a substrate, it willbe appreciated that that junction may be provided elsewhere, e.g.,provided that it still receives the flux. Moving the sensor to adifferent location on the same surface or moving it to another surfacemay require alternative calibration in some instances.

It will be appreciated that although certain example embodiments referto heat sensors or heat flux sensors, such sensors may be used tomeasure radiation, conduction, convection, and/or combinations thereof,e.g., at the same and/or different times. Such sensors in certainexample embodiments may additionally or alternative measure phasechanges in a product such as a window including, for example,condensation. For instance, if one of pads is dry and hidden (e.g.,concealed behind a radiation or other barrier) while the other isexposed to water condensation, one side of the junction will “see” aninflux of heat even though there is no temperature change.

With respect to the use of sensors to measure radiation, conduction,convection, and/or combinations thereof, it is possible in certainexample embodiments to measure these three modes with three differentsensors. For example, with respect to radiation, the Heat flux sensorsmay be calibrated using radiation heat sources that are consistentlyrepeatable sources and thus effective for calibration purposes. However,the fraction of the radiation absorbed by the sensor, or its emissivity(ε), in practice almost certain will not be 100%, so the absorbed heatflux will differ from the incident heat flux. In other words, anassumption is made that the sensor includes a “graybody,” whoseabsorptivity and emissivity are equal. Heat flux sensors can measure theabsorbed heat flux, regardless of its source or the mode of heattransfer. Sensors therefore may be coated black with carbon black, blackpaint, DLC, etc. (e.g., as indicated above), to help boost emissivity sothat the absorbed radiation is nearly equal to the incident radiation.The relation of incident and absorbed heat flux for a radiation sourceis given by the following equation:q″ _(absorbed) =εq″ _(absorbed).

With respect to conduction, when the heat flux is not from a radiationsource, emissivity is not necessarily an issue. For a conductive heatflux, for example, where the sensor is in direct contact with a heatedmaterial, the governing equation at the material surface is:Q _(inc) =Q _(abs) =−kA(dT/dx),where k is equal to the thermal conductivity of the sensor, and dT/dx isthe thermal gradient with n as the unit vector perpendicular to thesurface through which the heat flux is being measured.

Because the incident and absorbed heat flux are the same for a purelyconductive heat flux, a heat flux sensor will read the actual incidentheat flux. One caveat is that the sensor may need to have good thermalcontact. For instance, if the contact is poor, there will effectively bea high thermal resistance between the sensor and the material ofinterest, which can alter the sensor reading and in some cases make theminaccurate.

For convective heat flux, the heat flux equation is:q″ _(absorbed) =hΔT,where h is the heat transfer coefficient of the sensor, and ΔT is thetemperature difference between the sensor and the fluid.

The heat transfer coefficient is a function of the fluid's thermalconductivity and the fluid flow characteristics. Unfortunately, fluidflow can be complex and difficult to model. The heat transfercoefficient therefore may be by measuring the surface heat flux. Thisprocedure may assume that the heat transfer coefficient for the heatflux sensor and the surrounding system are the same, so that theincident and absorbed heat flux are equal. The accuracy of thisassumption will vary with different system configurations and materials.A calibration may be performed to help account for determined regularvariations.

Thus, it will be appreciated that all three modes of heat transfer canbe measured, e.g., in the manners described above. When radiation ismixed with the other modes, however, the question arises as to whatfraction of the heat flux should be corrected for emissivity and whatfraction need not be. The different modes may in certain exampleembodiments be isolated by, for instance, using a heat flux sensor in aradiometer configuration to in essence “view” only the radiationsources. If the modes cannot be differentiated experimentally, it maybecome desirable to make intelligent estimates of the relative fractionsof the heat flux each mode contributes. In these cases, the emissivityof the heat flux sensor may be made as high as possible to help minimizeerror.

Advantageously, the techniques described herein promote the developmentand qualification of systems (e.g., including windows and/or the like)that perform the same within a predefined tolerance. The solid-statesystem of certain example embodiments, which does not move,advantageously is rugged yet easy to manufacture. Moreover, certainexample embodiments need not be powered, e.g., because it generates itsown voltage, etc.

The terms “heat treatment” and “heat treating” as used herein meanheating the article to a temperature sufficient to achieve thermaltempering and/or heat strengthening of the glass-inclusive article. Thisdefinition includes, for example, heating a coated article in an oven orfurnace at a temperature of at least about 550 degrees C., morepreferably at least about 580 degrees C., more preferably at least about600 degrees C., more preferably at least about 620 degrees C., and mostpreferably at least about 650 degrees C. for a sufficient period toallow tempering and/or heat strengthening. This may be for at leastabout two minutes, up to about 10 minutes, up to 15 minutes, etc., incertain example embodiments.

The terms “peripheral” and “edge” used herein in connection with seals,for example, do not mean that the seal(s) and/or other element(s) is/arelocated at the absolute periphery or edge of the unit, but instead meanthat the seal(s) and/or other element(s) is/are at least partiallylocated at or near (e.g., within about two inches) an edge of at leastone substrate of the unit. Likewise, “edge” as used herein is notlimited to the absolute edge of a glass substrate but also may includean area at or near (e.g., within about two inches) of an absolute edgeof the substrate(s).

As used herein, the terms “on,” “supported by,” and the like should notbe interpreted to mean that two elements are directly adjacent to oneanother unless explicitly stated. In other words, a first layer may besaid to be “on” or “supported by” a second layer, even if there are oneor more layers therebetween.

In certain example embodiments, a glazing assembly is provided. Itincludes a first glass substrate; a radiation shield covering, directlyor indirectly, at least a part of a peripheral edge area of the firstglass substrate; and a dual junction solid-state heat flux sensor. Thesensor includes a first junction oriented in the assembly at a firstlocation at which radiation from a radiation source is receivablethrough the first glass substrate, a second junction oriented in theassembly at a second location that is blocked from the radiation sourceby the radiation shield, and circuitry configured to generate a signalbased on a differential between transduced voltages respectivelygenerated at the first and second junctions.

In addition to the features of the previous paragraph, in certainexample embodiments, a control module may be configured to receive thesignal and selectively generate an action responsive thereto.

In addition to the features of the previous paragraph, in certainexample embodiments, the action may correspond to the activation ordeactivation of a switchable product. For instance, the action maycorrespond to the activation or deactivation of a switchable product,activation or deactivation of a localized heating and/or cooling system,etc.

In addition to the features of the previous paragraph, in certainexample embodiments, the switchable product may include anelectrochromic film and/or a polymer-inclusive liquid crystal layer(e.g., of or including PDLC, PALC, and/or the like).

In addition to the features of any of the three previous paragraphs, incertain example embodiments, the control module may include a memory,the memory storing information about the received signal.

In addition to the features of any of the four previous paragraphs, incertain example embodiments, the control module may include a memory,the memory storing information about when actions are to be taken andone or more conditions that trigger each of the actions.

In certain example embodiments, a laminated product is provided. It mayinclude the assembly of any one of the previous six paragraphs, alongwith a second glass substrate, and at least one laminating materialprovided between the first glass substrate of the assembly and thesecond glass substrate. The sensor of the assembly is located betweenthe first glass substrate of the assembly and the second glasssubstrate. For instance, a switchable polymer-inclusive liquid crystalproduct may be provided, and the at least one laminating material mayinclude first and second laminating materials, the first laminatingmaterial laminating the first glass substrate of the assembly to theswitchable polymer-inclusive liquid crystal product, and the secondlaminating material laminating the second glass substrate to theswitchable polymer-inclusive liquid crystal product. In certain exampleembodiments, an insulating glass (IG) unit is provided. It may includethe assembly of any one of the previous six paragraphs, along with asecond glass substrate, and a peripheral edge spacer helping to maintainthe first glass substrate of the assembly and the second glass substratein substantially parallel spaced apart relation to one another. Thesensor of the assembly is located between the first glass substrate ofthe assembly and the second glass substrate. For instance, a controlmodule may be configured to receive the signal from the glazing andgenerate a report on the performance of the IG unit as a whole. Thereport may include a real-time U-value measurement and/or a historicalreport of U-values in certain example embodiments, the report maysuggest a likely failure of the IG unit as a whole, etc. In certainexample embodiments, a vacuum insulating glass (VIG) unit is provided.It may include the assembly of any one of the previous six paragraphs,along with a second glass substrate in substantially parallel spacedapart relation to the first glass substrate of the assembly; a pluralityof support spacers provided between the first glass substrate of theassembly and the second glass substrate; a peripheral edge seal providedaround peripheral edges of the first glass substrate of the assembly andthe second glass substrate; and a gap defined as including the areabetween the first glass substrate of the assembly and the second glasssubstrate and being within the peripheral edge seal, the gap beingevacuated at a pressure less than atmospheric. For instance, a controlmodule may be configured to receive the signal from the glazing andgenerate a report on the performance of the VIG unit as a whole, and thereport may include a real-time U-value measurement and/or a historicalreport of U-values, the report may suggest a likely failure of the VIGunit as a whole, etc. In certain example embodiments, an automotivewindow comprising the assembly of any one of the six previous paragraphsis provided.

In addition to the features of any of the seven previous paragraphs, incertain example embodiments, the radiation shield may include a frame orsash.

In addition to the features of any of the eight previous paragraphs, incertain example embodiments, the radiation shield may include blackfrit.

In certain example embodiments, a method of making a glazing assembly isprovided. At least a part of a peripheral edge area of a first glasssubstrate is covered, directly or indirectly, with a radiation shield. Adual junction solid-state heat flux sensor is connected to the firstglass substrate, so that a first junction of the sensor is oriented inthe assembly at a first location at which radiation from a radiationsource is receivable through the glass substrate, and a second junctionof the sensor is oriented in the assembly at a second location that isblocked from the radiation source by the radiation shield. Circuitry isconfigured to generate a signal based on a differential betweentransduced voltages respectively generated at the first and secondjunctions.

In addition to the features of the previous paragraph, in certainexample embodiments, a control module may be connected to the assemblyso that the control module is able to receive the signal and selectivelygenerate an action responsive thereto.

In addition to the features of the previous paragraph, in certainexample embodiments, the control module may be used to selectivelytrigger an action to be taken in a system external to the glazing,and/or an action to be taken with respect to the glazing.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

What is claimed is:
 1. A method of making a glazing assembly, the methodcomprising: covering, directly or indirectly, at least a part of aperipheral edge area of a first glass substrate of a switchable glazingassembly with a radiation shield, the switchable glazing assemblycomprising the first glass substrate, a second glass substrate, a heatflux sensor, and a layer comprising liquid crystal provided between atleast the first and second glass substrates; providing the heat fluxsensor so that a first junction of the heat flux sensor is oriented inthe assembly at a first location at which radiation from a radiationsource is receivable through the first glass substrate, and a secondjunction of the heat flux sensor is oriented in the assembly at a secondlocation that is blocked from the radiation source by the radiationshield; and providing circuitry configured to generate a signal based ona differential between signals respectively generated via the first andsecond junctions so that the switchable glazing assembly is configuredto adjust transmission of the switchable glazing assembly based on thedifferential by adjusting voltage applied to the layer comprising liquidcrystal.
 2. The method of claim 1, further comprising connecting acontrol module comprising circuitry to the assembly so that the controlmodule is able to receive the signal and selectively generate an actionresponsive thereto.
 3. A method of using a glazing assembly, the methodcomprising: providing the glazing assembly of claim 2; and using thecontrol module to selectively trigger an action to be taken in a systemexternal to the glazing.
 4. A method of using a glazing assembly, themethod comprising: providing the glazing assembly of claim 2; and usingthe control module to selectively trigger an action to be taken withrespect to the glazing.
 5. A method of making a glazing assembly, themethod comprising: covering, directly or indirectly, at least a part ofa peripheral edge area of a first glass substrate of a switchableglazing assembly with a radiation shield, the switchable glazingassembly comprising the first glass substrate, a second glass substrate,a heat flux sensor, and a switchable layer provided between at least thefirst and second glass substrates; providing the heat flux sensor sothat a first junction of the heat flux sensor is oriented in theassembly at a first location at which radiation from a radiation sourceis receivable through the first glass substrate, and a second junctionof the heat flux sensor is oriented in the assembly at a second locationthat is blocked from the radiation source by the radiation shield; andproviding circuitry configured to generate a signal based on adifferential between signals respectively generated via the first andsecond junctions so that the switchable glazing assembly is configuredto adjust transmission of the switchable glazing assembly based on thedifferential by adjusting the switchable layer.